Urea-formaldehyde type resinous product



Patented Feb. '27, 1940 PATENT OFFICE nasa-ronmmsnrnn 'rrrs aasmous raonnc'r Carleton Ellis, Montclair, N. 3., assignor to Ellis- Foster Company, a corporation of New Jersey No Drawing.

Application March 13, 1939, Serial No. 435 .640

16 Claims. (01. zso-ss) This invention relates to resinous products derived by aldehydic condensation of urea and/or thiourea and/or other resinifying urea derivatives and the cellulose complex thereof.

The object of the invention is to provide a complex adapted for use in the plastic arts.

The complex may be considered from two standpoints: (l) as a primary complex; and (2) as a secondary complex.

10 The primary complex is constituted by either (a) urea aldehyde condensation products, particularly such products derived with the aid of formaldehyde; or (D) such products incorporated with a modifying agent of resinification, such as the condensation products of thiourea and an aldehyde, specifically formaldehyde, or a resinous material of the type of an acetone resin made by reacting on acetone with an aldehyde such as formaldehyde or various other resinous modify- Ea'; ing agents, as will subsequently be more fully described.

Reference is made to companion .copending applications for subject matter utilized in carryout the present invention and described at least 26 in part in those several applications. In application, Serial No. 689,165, filed January 25, 1924, entitled "Light synthetic resin and process of making same, now Patent No. 2,075,804, granted April 6, 1937, there are described resins of the 30 urea type, such as the condensation products of urea and formaldehyde and methods of making such resins, the claims being particularly directed to the urea resins produced by the utilization of acids, either inorganic or organic acids, and

35 the further treatment of such condensation products by heat or by heat and pressure to modify the characteristics of those condensation products, including also the reaction withthe resins, of agents which afiect the characteristics of the 40 condensation products, such as tempering agents,

including casein, etc.

In companion application 694,420, filed February 21, 1924, entitled -White plastic resin and process of making same, there is disclosed and 46 claimed molding compositions and molded articles, as well as methods of producing such compositions and articles, produced with urea resins, particularly urea-formaldehyde resins incorporated with flllers and pigments, and more partic- 50 ularly molding compositions containing ureaformaldehyde resins that are variously colored to produce multi-colored molded articles,etc.

' In companion application, Serial No. 735,600, filed September 3, 1924, entitled Urea product 465 and process of making same," now Patent No.

2,057,672, granted October 20, 1936, there is disclosed and claimed laminated products carrying sheet material cemented or bound together with urea resins, and methods of making such laminated products, and also claims to the resins and methods of making the resins produced by simultaneous reaction of aldehydes with both urea and thiourea or related complex products.

In companion application, Serial No. 742,719, filed October 9, 1924, entitled Laminated pressboard and multi-colored articles and process of making same, there is disclosed and claimed laminated products or multi-colored articles made from variously colored fragments of urea resins as well as sheet material, such as paper, 5 carrying the urea resins.

In companion application, Serial No. 28,505, filed May 6, 1925, entitled Synthetic resin and process of making same," now Patent 1,846,853, granted February 23, 1932, which is a division of companion application, Serial No. 689,165 referred to above, there is described and claimed the resins and methods of producing same in which the urea resins are produced by first reacting the ingredients, such as urea and formaldehyde in an alkaline medium followed by acidification, as well as methods for producing such condensation products when the reacting ingredients are processed together under more than atmospheric pressure, and in the presence of ingredients that modify the character .of the condensations obtained.

In one modification of the present invention urea condensation products in conjunction with sulphur-containing resins are used together to form the basis of a plastic or resinouscomplex,- including the employment of mixtures of urea and thiourea reacted'with formaldehyde to form a plastic complex. In the last mentioned application I have also indicated that the reaction 40 between these urea materials and the aldehyde can be carried out in acid, alkaline or neutral solution. The present invention is in part congel vcerned with production of an initial reaction product under conditions which are substantially neutral.

Reaction within the confines of neutrality.- Reaction within the neutral zone, that is in that borderline between acidity and alkalinity, has in years past been determined by various indicators such as litmus. In my earlier applications where reference has been made to the, conduct of the initial reaction under conditions of neutrality, I have made such determinations of neutrality by means of litmus, and the like. In recent years the hydrogen ion concentration method of determining acidity, alkalinity and neutrality has come into use with the provision of delicately adjusted indicators to make possible more accurate determinations than heretofore available with the aid of litmus and the like. According to authorities, litmus indicates neutrality between a pH of 4 or 5 on the one hand (acid side) and a pH of 8 on the other hand (alkaline side) Within these limits there exists what may be termed a neutral zone defining neutrality as originally expressed in terms of litmus or similar indicators. In the present invention I prefer to conduct the initial reaction between formaldehyde and urea and/or thiourea, etc., within the limits of such neutral zone. If the formalin solution employed is not adequately neutral it may be suitably neutralized to bring it within this neutral zone.

Period of heating.-Reaction between the urea materials and the formalin may be carried out at elevated temperatures but below the boiling point of the liquid, as indicated in several of my earlier applications. Or a definite temperature of reaction, namely, the boiling point may be taken and the time of heating reckoned on that temperature. Within the neutral zone the reaction takes place with a sufficient degree of rapidity at the boiling point (which is usually a degree or two below 100 C.) permitting a syrupy product to be prepared by conducting the reaction for periods ranging from 15 minutes to 2 or 3 hours. Considered from the standpoint of pH the time of reaction may be stated in a very rough way to vary inversely as the hydrogen ion concentration increases. During the heating there is usually a very slight increase in pH value. A reaction mixture which in the cold showed a pH of 6, after minutes boiling showed a pH of 5.3, after 1 hour pH 5.2 and after 1 hours pH 5.1. At this stage the reaction mixture gelled. In another observation a batch having an initial pH of 5.6 showed pH 5.1 at the end of half an hour. The change in pH by heating, therefore, is very slight and apparently does not at any time carry the reaction mixture out of the neutral zone when the reaction has been initiated under said neutral con ditions. Therefore operating under these conditions I may start with an initial pH ranging from 7% or 8 down to 4 without sacrificing that condition of neutrality. Preferably the reaction is carried out at atmospheric pressure employing a reflux condenser which substantially prevents the admission of air during the reaction. In other cases reaction may be carried out in autoclaves at pressures above atmospheric.

Relation of heating to drying.The time of heating is in some manner connected with the release of moisture from the resinifled material during the drying period. Certain conditions are imposed with respect to drying temperatures in order to prevent conversion of the material during drying to a stage where it will not flow properly in the mold. It is of great importance to avoid this precuring condition because for molding purposes a composition must be prepared which will soften and flow freely to all parts of the mold forming sharp edges or otherwise taking a clean-cut impression of the mold and thereupon to set promptly, that is cure, yielding a hard thermo-set shaped article. As will be subsequently more fully discussed, a material of the cellulose type preferably is incoroorated with the resin, especially while the latter is in its intermediate syrupy stages. Thereupon the material is dried. This may be conducted, as I have specified in certain of my patent applications, in a vacuum dryer. A procedure which allows the employment of cheaper equipment is drying in the open as, for example, air drying followed by exposure to a gentle heat. A simple manner of drying is to expose the composition on screens made from nickel or Monel metal wire placed in a drying room through which a circulation of air is maintained to heat the material to a temperature of, say, to C. It is possible to advance the temperature to or C. or even higher in some cases, provided the time of heating is not protracted to cause objectionable pre-curing. While the composition is still quite moist the higher temperatures may .be employed rather freely without danger of precuring. But as soon as the bulk of the moisture has departed then there arises this danger. It is better, therefore, to dry at lower temperatures. for example, around 50 C., or perhaps slightly higher, to avoid pre-curing difliculties. Drying at this temperature, however, might be expected to be a slow operation, since the cellulose material would be likely to hold moisture in a rather rententive manner. However, there appears to be a relation between theperiodof heating of the initial reaction mixture to that of drying. If the reaction is carried forward in the liquid stage, that is the initial stage, as far as is possible consistent with molding requirements, the escape of water from the composition in the dryers is more rapid than when the reaction has not been carried so far. Apparently there is a condition akin to case-hardening when the reaction has been less advanced in the liquid stage and pushing the temperature to an elevated point in order to force out the moisture only aggravates this condition and as a result by the time the product is well dried it has become pre-cured and will not flow freely. The present invention, therefore, contemplates carrying forward to its reasonable limitations the initial heating in the liquid stage and then preferably drying at a very moderate temperature. In this way prod ucts having remarkable qualities of flow in the mold, coupled'with rapid curing, are obtained.-

Avoidance of discoloring meta1s.-Molded products of the character obtainable in accordance with the present invention have the advantage over those made from phenol formaldehyde resins, and the like, of their light color or lack of color, with the resulting opportunity of the introduction of colors which will tint the molded article to delicate shades or tones, as may be required. Certain metals, however, have a strong discoloring effect, iron being the principal offender. The reaction preferably should be carried out in glass or enamel vessels or in those made of aluminum, Monel metal, or similar nondiscoloring metals. In drying, as indicated, Monel metal screens, and so forth, of a kind which will not cause discoloration preferably should be used.

Cooling the Reaction Mixture.0n the large scale a reaction receptacle may be provided with a coil through whicha heating or cooling fluid may be introduced. For example, steam may be passed through in order to heat the mixture and then, if the reaction becomes too .violent, cold water may be passed through these same coils to check the turbulence of the reaction.

Incorporation with cellulose.--As stated in several of my prior applications, cellulose in its various forms maybe employed, including the crudeform, such as ground wood or wood fiour, and more purified forms of cellulose, such as paper, cotton flock, linters, and the like. A suitably purified form of paper is alpha cellulose in sheet form. In incorporating cellulose with the syrup care should be taken to have present enough water to permit all the fibres of the cellulose to be well impregnated with the solution. Preferably the syrup, diluted with water or undiluted, as the case may be, is mixed while hot with the cellulose. The latter preferably is also heated prior to introduction into the syrup. Thorough impregnation is important in order to secure that change in the character of the cellulose which results in the production on hot pressing of translucent articles. Impregnation by a vacuum and pressure.Impregnation of cellulose fibre may be conducted by a vacuum and pressure process, that is, the fibre as such or in paper form or otherwise is placed in a closed receptacle and the air withdrawn to produce a high vacuum. The urea resin impregnating syrup then is run into the receptacle and pressure is applied. In this way the fibres are better impregnated. This is desirable in particular, when paper of some thickness is used. Impregnation adequate to fill the canals of the fibres in a substantially complete manner tends to yield the highest degree of transparency or translucency in the finished molded article or laminated sheet. A vacuum of, for example, 20-25 inches or thereabouts of mercury may be employed followed by a pressure of 50-100 lbs. or higher, as desired.

Introduction of coloring materials-Owing to the colorless character of the product if made according to the foregoing directions, only a small amount of a dye is required to create a strong coloring effect. For example, from a half gram to one gram of a dye such as .rhodamine suffices to strongly color from 5 to 10 kilos of the composition. Soluble dyes may be added to the syrup before it is reacted with the cellulose material. Mineral pigments may be incorporated with the dried composition during ball mill grinding, if this step is carried out. When the syrup has been made with the aid of thiourea or similar sulphur resins, care should be taken not to use a pigment which reacts with sulphur to cause an undesirable change in color.

Drying the comp0siti0n.-If the filler is in sheet form as, for example, alpha cellulose, impregnation may be conducted, for example, by passing the dry sheets through the hotsyrup. If the cellulose is in loose fibrous form, it is stirred thoroughly with the hot syrup and the product in either case is preferably dried at a temperature ranging from -75 C., the manner which I have already indicated being suitable. I have proposed drying at room temperatures and at higher temperatures ranging from -60 C. Vacuum drying up to 50 C. is usable. In some cases higher temperatures are employed as, for example, when drying is carried out in a vacuum dryer. In that particular instance, however, the overcuring resulted under the conditions of preparation of the material. Clear glass-like material has been obtained by vacuum drying up to a temperature of 90 C. With an asbestos fibre filler vacuum drying up to 90 C. was employed. In some instances drying was carried out by exposure at 90 C. in a vacuum dryer for one hour, until the mass had a crisp and brittle feel. In the latter instance the syrup was incorporated with a mixture of wood flour and titanox, or titanium oxide. Other example of drying temperatures include drying sheeted material for ten minutes at 80 C.

Grinding the composition-When a composition is required which is to be pressed in a plunger mold or used for pressure-casting, preferably it should be ground fairly fine, or at least the coarse lumps of matted material coming from the dryer should be broken up. A suitable procedure is to place the dried charge in a ball mill, which has no interior parts of irdnor other discoloring metal, and grinding untilfile composition has been reduced to a stage of li eness such that it will pass a 40 mesh sieve. A good determination of the degree of drying can be secured by a preliminary test in a small way in a ball mill. If drying has been carried through to a stage where the product has a crisp feel, grinding will take place readily and the product, other things being carried out properly in accordance with the foregoing, will mold nicely. If the drying has been inadequate, the moisture present may. tend to cause lumping and imperfect grinding. In such case the material should be placed again in the dryers and the moisture removed. The quality of grinding, therefore, is to a very considerable extent an index of the degree of drying and when one is inexperienced in making the material and cannot judge readily by the feel of the dried composition whether or not it is sufliciently moisture-free, a ball mill test may be employed. While I have specified a product passing a 40 mesh sieve, I may employ finer or coarser gradations, as desired. Of course, when the product is to be handled in sheet form grinding will not be required.

Introduction of mold lubricant-During the grinding pigments and mold lubricants may be introduced. For light colors a suitable mold lubricant is zinc stearate, although other insoluble metallic soaps such, for example, as aluminum palmitate, may be used in certain cases. In general, however, a metallo-organic lubricant should be used which has no discoloring effect and zinc calcium or magnesium soaps in finely powdered or precipitated form may be used advantageously. From one-half per cent to one per cent of zinc stearate may be added to the charge in the ball mill. Other mold lubricants, such as stearic acid, wax, and the like, may be employed in special cases. Introduction of metallic soaps tends to reduce translucency. In some cases 2 or 3 per cent or more of zinc stearate may be added to yield an opaque molded product which may be given a tint to resemble ivory. However, translucency is a highly important property and any additions which tend to reduce it are undesirable. For this reason metallic soaps if used should be employed in minimum amounts so as to impair translucency as little as possible.

Molding pressures.-'I'he composition then is ready for molding, which may be conducted by means of charging the material into the cavities of plunger molds and submitting to hot-pressing. In molding the compositions of the type specified herein I find a certain range of pressures yields shaped products of good definition and surface finish. As exemplary of the pressures that may be used, mention may be made of a pressure of one thousand to two or three thousand pounds. The precise pressure selected within this preferred range will depend on the fiowability of the composition. Thus a pressure of 2,000 lbs. is used in some cases, while 3,000 lbs. is

used illustratively for forming laminated sheets. The preferred pressure range therefore extends from one ton to one and one-half tons per square inch of mold surface and this pressure should ordinarily be indicated by a gage on the press. There are conditions where a departure from this preferred range may be required, especially in the direction of higher pressures for certain resistant compositions, particularly those having a high content of special fillers.

Temperature of molding.-Unlike phenol formaldehyde resinous plastics which are capable of being subjected to relatively high temperatures without disturbance, the molding compositions made with the urea type of resins are notably sensitive to temperatures above a certain relatively low limiting point. In order to cure phenol formaldehyde resinous compositions as rapidly as possible, it has become customary to mold at fairly high temperatures, ordinarily too high for the urea resin plastics. As a result of the technique which has developed in the phenol formaldehyde plastics, operators familiar therewith are liable to overheat the urea resin plastics and condemn them because of the surface imperfections resulting from such overheating. Throughout my earlier applications I have pointed out the danger of blistering and disintegration unless the molding operation was carried out below such limiting or maximum temperatures. On the other hand, curing is too slow when molding is carried out at an inordinately low temperature. Moreover the rate of transmission of heat to the mold should be considered. Temperatures registered by electrically heated platens usually should range between or C. up to about 150 C. A good optimum temperature range is between and C. In molding with steam heated platens the transmission of heat is usually slower and misleading results are returned if the assumption is made that the temperature of the mold when steam is used as the heating agent is equivalent to that represented by the steam pressure on the supply line. The temperature of the mold in these conditions is usually substantially lower. Examples of temperatures employed in molding urea resin compositions include 110--130 C., 125-150 C., and specific temperatures within these such as 120 C. and 130 C. In another case 130 C. was used as a maximum, this being a desirable maximum for products in which whiteness or lightness of color is to be effectively preserved; and elsewhere a temperature of C. Likewise in the production of laminated material, temperatures of 120-130 C. are recorded.

Avoidance of blistcring.-I call attention to the efiect which the presence of cellulose imparts of greatly reducing blistering tendencies. Therein I note the manner in which the introduction of wood flour (with or without a white pigment or other pigment material) reduces the tendency to blistering. This and other effects which have been previously recorded by me indicate an action by the cellulose material to be something more than that solely of the role of a mere extending agent or filler.

If mechanical water is well removed from the composition by carefully drying up to, say, 65'l5 C., a substantial proportion of cellulose (at least 25 per cent of the composition) has been used and the preferred maximum of 150 C. molding temperature is not exceeded, blistering dimculties are unlikely. Water which may be present in the mold and become converted into steam with formation of blisters is in part due to the reaction of condensation which may liberate water during the thermo-setting. Such water may be termed latent water. While mechanical water may be removed by drying, the latent water liberated in the mold cannot be readily freed from the molded article except that part which is liberated near the surfaces of such articles. The cellulose material, especially hydrocellulose, is useful in absorbing latent water. Thus a hydrocellulose cellulosate' which may have become considerably de hydrated during drying can become more or less rehydrated during hot pressing due to absorption of latent water of condensation. This, therefore, in a sense is merely a transfer of water.

Breathing the moZd.When a. composition contains more than a certain proportion of mechanical water and/or free formaldehydes, molding will be difficult unless the plunger of the mold is raised once or twice during the pressing to allow the escape of gases and vapors. This is especially noticed in the case of urea resin alone, in the absence of thiourea condensation products. The step of releasing the mold in this manner is termed breathing the mold." It is not a desirable step, since it constitutes one more operation to receive attention. Below I have set forth a composition essentially a urea-formaldehyde condensation product with a content of cellulose material, which does not require breathing when used in a variety of molds.

Spraying with water.0n the other hand, there are certain cases where the addition of water is helpful in improving flow. Compositions which have been overheated during the drying, or for other reasons do not flow freely, may sometimes be improved in flowing qualities by very slightly moistening with water as, for example, by atomizing water into the pulverized material while the latter is being agitated. In this way a rather low grade product may be obtained which can be used for purposes not requiring a high quality product. It should not be inferred from this statement, however, that such a procedure of moistening is desirable. It is only a makeshift which sometimes can be employed.

Duration of curing in the m0ld.-The curing time shou d be rendered as brief as possible. For thin moldings a molding time of from 2 to 5 minutes is desired. For thicker articles up to 10 minutes, or even longer, may be needed. The composition, therefore, should be as heat sensitive as is feasible consistent with adequate flow. Sometimes it is desirable to add to the dry composition a catalyst such as urea phosphate or nitrate which will speed up the curing time and increase water resistance.

Curing catalysts-As noted in the foregoing, acceleration of curing by the addition of catalysts sometimes may be required. These m'iry'be direct acting, that is capable of exerting acceleration of reaction at all times, or they may be latent, that is active only when a given temperature is reached. I have noted that rapidity of molding is a very important consideration owing to the high labor cost of such manipulation. Hence any procedure which will shorten the time the composition is taking its final shape in the mold is of importance. With white articles sensitive to higher temperatures than those specified, the duration of molding may be adjusted or accelerated by the presence of an acid catalyst present in an amount adequate to meet the particular requirements. I have pointed out that sometimes it is desirable to carry out the initial reaction between urea and formaldehyde, paraform or other aldehyde employed, in an alkaline medium to the point where particles begin to precipitate and that instant to arrest the action by the addition of acetic or other'acid to approximate neutrality. If the alkali is allowed to react beyond a certain point the reaction batch may solidify to a magma or white pasty substance which cannot be used advantageously for pressure-casting, although it may be dried out and used in hotpressing. Therefore, before the liquid starts to thicken with separation oi one reaction product, it is neutralized. Thereupon an acid catalyst may be added in such propmtion, with or without cooling,- as may be desired with reference to the speed of setting. Citric and ox alic acid, phthalic anhydride and other acid bodies mentioned in my prior applications may be used for the purpose. In some cases urea phthalate, and the like, may be employed. 'As latent catalysts there may be mentioned some of the amine hydrochlorides, also various salts of alkyl sulphuric acid, e. g., sodium or barium -ethyl sulphate which decomposes at 120 G. into ethyl alcohol and sodium bisulphate. The latter is active accelerator of hardening. The proportion of catalyst may range from less than $5 of a per cent up to several per cent. In some cases fluxing catalysts may be used, that is bodies which tend-to have a fluxing effect in the first instance and then as the temperature of the mass in the press increases a breakdown occurs with liberation of catalytic material.

Translucency.A very important feature of articles made from cellulose and these urea condensation products is their translucency. This is a quality which hitherto has been diflicult to secure in non-inflammable plastic material of relatively low cost. Translucency may be aided by thorough incorporation of cellulose and the urea syrup, preferably allowing adequate time for the hot solution to react with the fibre. Drying, moreover, should be thorough. Mineral pigments should be absent, in their place soluble dyes being used.- As already noted under lubricants, the presence of more than a very small percentage of zinc stearate tends to decrease the translucency. Another method of improving translucency is to use fairly high pressures during molding, as, for example, 2,000-3,000 lbs. Higher pressure possibly brings about further reaction between cellulose and the urea material to form more fully reacted cellulosates, thereby increasing translucency.

Opacity.0n the other hand, when opaque products are desired the addition of a few percent of a mineral pigment suflices. If a white article is desired a number of the white mineral pigments are available, particularly those which are not discolored by sulphur (this consideration applying if a suphur resin is present). Pure titanium dioxide, or its commercial embodiment known as titanox, is a useful white pigment and may be used in conjunction with the cellulose in various proportions. Lithopone is even better in some respects. In no case does it appear necessary to employ more titanox than corresponds to equal proportions by weight of this titanium pigment and cellulose. In the majority of cases a considerably lower proportion of the mineral pigment suffices. This is notably true when the pigment possesses a strong pigmenting power.

Molding then baking.I have disclosed the step of hot molding, followed by a baking or stoving treatment. The composition can be given a preliminary rapid mcldingand the shaped article in a'semi-cured condition is then placed in an oven and subjected to a baking temperature, for example, 0., for aperiod of two or three hours. This brings about a further hardening and increased resistance to'water. In other cases a milder heat may be employed. Thus molded articles or pressed sheets may be baked at a tem perature, for example; of 60-70" C. for half an hour or longer, depending on the thickness of the pressed product. A baking range of Gil-100 C. is therefore permissible, but care should be taken that the baking oven-is not too hot when the semi-cured articles are first placed therein. otherwise warping may ensue. The danger of warping is reduced with the degree of hot pressing. That is, if curing has advanced to a very considerable extent in the mold, warping in the baking oven is not likely to occur.. Therefore the most careful watch should be taken with only slightly cured pressed articles, as these are more sensitive to warping and therefore will require initially a correspondingly lower baking temperaof different colors 9. thick sheet or block may be built up which if desired may be cut into various shapes, the cut edges of which will show alternating colors.

In making the laminated material it is possible also to insert photographs or pictures which, provided the pressing is carefully done, may be embedded in the sheet and thus protected.

In other cases metal flakes or powder such as gold flakes or aluminum powder may be scattered through the laminations. Again strips of the treated paper may be wound on a mandrel to form a cylinder, cone, and the like, and the mass subsequently pressed in the manner to be described.

A particular feature of the present invention is the production of sheets which even though of considerable thickness will transmit light. Thin layers arepractically transparent andthe thicker layers are of an opaqueness ranging from that of frosted or ground glass to a higher degree of opacity.

In one form of the invention '1 may take clippings or shreddings of the treated tissue or other paper and compact them by hot-pressing to produce a striated molded article, sheet or block. When these clippings are made from paper that has been dyed in different colors, a multi-colored effect is obtained by mixing the shreddings of different colors and hot-pressing.

Furthermore, it is possible to take portions of the shreddings and place in different parts of the mold so that the colors in a given sheet, block or molded piece will be segregated.

In carrying out the molding or hot pressing of such material, the shreddings may first be tableted if desired and then molded at the requisite temperature. The molds may have surfaces which give an embossed effect or print in raised or depressed letters any desired name or emblem. In some cases fillers may be incorporated with the paper sheets.

Veneering.-In the same category as laminations are included veneered products made by hot-pressing a facing on a heavier or stifier backing or support. The latter may be, for example, wall board in any of its forms or other thick supports of pulp, and the like, including slate, glass, wood, but in particular any material capable of withstandingthe mechanical and temperature stresses arisingin the operation. Sheet metal or other metal supports may be used in somecases. The support frequently is a plastic of itself and may, in some cases. be of the urea resin type. Thus a plastic may be made from urea resin or urea-thiourea resin, or other modifying resin, incorporated with a relatively high proportion of wood flour, wood raspings, wood chips, sawdust, or mixtures of these. Preferably I employ in such backing composition at least 50 per cent of the cellulosic material and more often from 60 to per cent thereof. I have been able to use wood fiour made from soft wood in the proportion of '15 per cent of the latter to 25 per cent of the resin solids and have, in some cases even exceeded that proportion. When hard wood of greater density is used, even higher proportions are possible. Using a light colored wood flour, the resulting molding, if pigment has not been added, will normally be of a brownish color, more or less translucent. The high proportion of cellulose usually does not permit the complete disappearance to the eye of anyfibres, a few of these showing after the reactons of hot-pressing have rendered infusible or converted the major portion of such fibrous material. Thus for such backings I preferably increase the percentage of fibre beyond the absorption point, that is, the point where fibre under hot-pressing ceases to be readily absorbed, dissolved or reacted by or with the urea plastic binder.

Using such material as the backing, I may pro-- vide a surfacing material consisting of a number of sheets of impregnated tissue paper prepared, for example, as set forth in Serial No. 142,- 719, or I may use a single rather heavy sheet. of light colored cellulose, such as alpha cellulose. The thickness may be as required according to the desired depth of veneer. The sheet of material may be suitably colored by means of dyes or pigments. On its upper side a very small percen"tage of zinc stearate may be included in order to allow the pressed surfaces to be readily released from the mold. The well-dried sheetin suitably prepared, while hard and crisp at room temperature, shows plasticity at, say, 60 C., so, that the sheets can be bent over shaped pieces or rounded or bevelled edges of a support. when the supporting structure is of steel and adhesion thereto is desired, the steel or other metal therefore should be well cleaned. Zinc stearate or other mold lubricant preferably should not be present on the under side of the impre nated paper which is to contact with the metal form or support.

Veneering pr0cedure.--Difierent steps mav be adopted, depending on the precise result desired. In one case, for example, impregnated alpha cellulose in sheet form is laid in the bottom of a flat mold, e. g., a panel mold, and over this is spread to considerable depth a backing composition in powdered formmade from urea resin (or urea-thiourea resin) and ground wood in high proportion. The mold cavity thus having been filled with the charge, hot-pressing is conducted to weld all together. In this way a backing perhaps ,5 to 5 inch in thickness may be surfaced with a veneer A to inch in thickness. The alpha cellulose or sulphite fibre sheet may, 5 as indicated, be tinted to anydesired color and if dyes are used instead of mineral pigments the result is a decorative translucent veneered effect wholly covering the brown colored, but strong and rigid backing. Such veneered sheets, panels, and other shapes, may be made relatively cheaply and have many prospective uses.

Another method of veneering is to place the powdered composition in the mold and hot-press to form a partially cured backing. On this place a sheet of alpha cellulose and again press to complete the curing of the backing and to cement the cellulose veneer in place. When desired, special designs may be prepared by cut-outs of different shapes which can be laid on the surface of the backing to fit nicely as, for example, like parts of a jig saw puzzle and when these multicolored pieces of the veneer or material are pressed there may be obtained various futuristic or other designs as desired.

Tiles suitable for bathrooms, and the like, may be made in this way or by any other veneering procedure within the scope of the present invention.

Shaped neneer.It is proposed to manufacture various bulky articles, such as lamp bases, urns and heavy decorative bodies, chair backs, arms, rungs, legs, and other furniture parts or requirements, bathroom equipment, and so forth, by preparing a shaped base or form of relatively cheap material and laying over this an impregnated sheet as described above, suitably colored. The sheet is warmed sufficiently to become plastic so it may be bent or wrapped about all or such part of the form as is required. Then the wrapped form is placed in a hot-press having a mold to correspond and the veneer is thereby pressed and shaped into place to conform to the base and to give the latter a decorative finish.

Plunger veneering.--This step may be illustrated by the method of covering a tapering chair leg, square in cross section, with a veneer of plastic composition as aforesaid. A mold cavity is provided slightly larger than the chair leg and the molding composition placed therein. Then the leg is forced into the composition while the latter is being heated, thereby to form a veneering finish.

Extrusion-Rods, tubes, chair legs and rungs, pipes for liquids, and the like, may be prepared by extrusion downward from a suitable die of the foregoing plastic. This treatment may be followed by cautious baking, if desired. The same procedure of extrusion may be utilized to form elongated masses shaped like boards or planks.

Flaming-For extrusion purposes or possibly in other cases, when a more plastic material is required, there may be added various fluxes, such as glycerine, glycol, diethylene glycol, and so forth. In some cases the addition of 2 or 3 per cent of thiourea in the charge when it is being ground in a ball mill serves to bring about adequate fluxlng.

Incorporation of other resins and plastic bodies.--In the foregoing I have referred to various modifying resins, such as phenol aldehyde resin, acetone aldehyde resin, sulphur phenol resin, and others. Various proteids, as indicated in my prior applications, may be used as modifying agents, including casein, glue and gelatine, Irish moss, algin, albumin, dried blood, and the like. These may be used in all proportions and therefore it is not necessary to set forth any specific formula. Vinyl resins, being capable of production of a light color, may be used in some cases with the light colored urea resins to yield various products such as those described above in which the vinyl resin exerts a modifying influence. By urea resin I include also urea-thiourea resin, and the like.

Water resistance.-Tiles and many other articles, such as bathroom equipment, must exhibit water resistance and for this, purpc-e it is desirable to use thiourea in conjunction with urea. The higher the proportion of thiourea the more positive the water resistance. It is, however, not necessary to go beyond a certain proportion in order to secure sufiicient water resistance for all practical purposes. Thiourea is more costly than urea and therefore should be used in as low aproportion possible consistent with meeting commercial requirements. Even as low as 1 part of thiourea to 9 parts of urea has a considerable influence on the action of moisture. While a composition made from urea formaldehyde resin alone will give molded articles which in the course of time lose their glossy finish, due to action of moisture, the same compositions in which, however, thiourea has replaced the urea to the extent of 10 to 20 per cent hold the finish in much more durable manner. For most purposes a proportion of thiourea to urea is the max mum required of this more expensive ingredient.

Printing bl0cks.Using the plastic of the present invention I may make printing blocksor printing plates which may be molded directly from the original as a matrix. Such molded printing blocks may, if necessary, be hardened further by baking. Such blocks may be required to stand pressures of 450 lbs. per square inch. Type metal will stand only about 300 lbs.

Successive additions of cellulose.-A procedure of significance from the manufacturing standpoint is the two-stage or multi-stage addition or incorporation or cellulose, such as alpha cellulose, cotton flock, linters, and especially ligniform material such as ground wood or wood fiour. When compositions are made containing a relatively high proportion of cellulose, there is obtained a great bulk of material requiring a considerable time to dry thoroughly. When the cellulose has been thoroughly wetted with the urea syrup, as the latter dries it goes through a gelatinous stage with possible difliculties from case-hardening or incrustation preventing thorough drying. If the temperature is raised to create a relatively strong heat, there is danger that the resin will become pre-cured. It is possible, however, to incorporate only part of the cellulose, using just enough to act as an absorbent for the syrup, e. g., to a syrup containing 60 parts total resin solids use 40 parts of wood flour. By thus using in substantially absorbing proportions or preferably optimum absorbing proportions, there is only a moderate mass of material (relatively considered) to be dried. After drying and preferably when incorporating pigments, mold lubricants, and the like, in the ball mill, there may be added at any suitable stage, but preferably after the impregnated cellulose has been ground, an additional quantity of the cellulose material which is unimpreg nated, that is, the normal fibre or ground up wood stock. A thorough mixing is made of the impregnated'and unimpregnated cellulose either, as indicated, by ball an equal amount, 1. e., 100 parts of wood flour as the sequential or secondary cellulose. Thus there would be obtained a mixture in which 40 parts of wood fiour impregnated with 60 parts of the resin were mixed with 100 parts of unimpregnated wood fiour sequentially added, giving a finished molding composition with 30 per cent urea binderto '10 per cent wood flour. Similarly there may be added as the sequential charge 125, 150, 200 or 300 parts wood flour, giving percentages of the latter reckoned in the finished molding composition as about 27%, 24%, 20% and of binder respectively.

Disappearance of ligniform structure-As I have indicated in certain of my co-pending applications, there appears to be, to some extent at least, a solution or absorption of cellulose by the resinified urea material when the reaction of hardening or curing is allowed to take place under heat and pressure. In any event, there is to the eye a disappearance of fibre to some extent which constitutes virtually a delignification. Wood flour with its component of lignin appears to be especially useful in this respect, which may be due in part to the presence of the lignin. When additions of wood fiour substantially beyond the absorptive capacity of the urea component are employed there may be obtained after pressing articles somewhat resembling wood which may be used as artificial lumber.

Addition of catalyst to the sequential cellulose charge.-After drying the composition with its primary charge of cellulose, the introduction of the secondary or sequential charge of cellulose to the dry batch permits of the addition of catalysts in a disseminated form, i. e., distributed in the pores of the particles of the sequential charge. Thus an acid catalyst, such as boric, phosphoric,

phosphomolybdic, silicotungstic, or other mineral acid or acid salts, e. g., bisulphates, alum, zinc chloride, and the like, alkyl sulphuric acid, various organic acids, such as formic, acetic, trichloracetic, lactic, citric, tartaric, succinic, phthalic salicyclic acids (or their anhydrides, as the case may be), singly or in admixture, dissolved in water or other appropriate solvent, and the sequential charge oi, for example, wood flour is wetted with the solution. Each particle of the wood flour thereby receives its quota of the catalyst. The latter then is air-dried or heated as may be required to remove moisture or solvent. Volatile acids such as formic and acetic acids, although mentioned in the foregoing, are not considered as suitable because the cellulose material cannot be as thoroughly dried without volatilization of a part of such acids. The sequential charge of cellulose if thoroughly dried serves an important function with respect to prevention of blistering, as will be noted later.

Acidulated wood flour catalyst.-Wood fiour varies with the grade of the wood, depending on whether pine, spruce, fir, and the like, are employed inits production. Cedar sawdust or cedar wood flour has characteristics different from the -...,ter, although in some cases of an alkaline na-* ture to render the whole catalytic in bringing about rapid curing in the mold. If the catalyst is introduced in this way it does not come into active contact with the urea resin binder until the latter is molded under the heat and pressure of the mold. Different types of cellulose may be used for the primary and for the secondary charge. For example, a very finely ground pine wood may be used as the absorbent charge and cedar sawdust'or flour used as the secondary charge.

Bone-dry secondary cellulose-When the urea resin material is reacted under heat and pressure to cure it, a certain amount of volatile material, principally the latent water of reaction, is liberated. There is also usually present some mechanical water which has not been thrown oil? completely in the drying step. This water may be a disturbing factor in the mold, causing blistering. The difliculty is especially noticeable with urea formaldehyde resin. that made from urea-thiourea formaldehyde being less likely to blister. However, troubles arise in both cases. Breathing the mold is one way of avoiding blistering, but it is an operation which should be avoided if possible and is not always a certain remedy. By using a secondary charge of wood flour which has been heated thoroughly to render it quite dry the composition acquires a high proportion of the water absorbent. The absorption by the bone-dry wood flour of that amount of moisture which normally would be present suffices to take up all water otherwise creating dis turbing conditions in the mold and this compensation of water evolution allows the production of smooth, well molded articles, free from blis tering.

A considerable number of illustrations are hereinafter given in which the same ratio of urea, thiourea and formaldehyde is maintained. This is illustrative in that it affords a desirable basis for comparison. However, by using these stated proportions for comparative purposes I do not wish thereby to limit myself either to proportions orto the precise character of the raw materials, it being understoodthat I may make combinations and additions in various ways and with various materials within the scope of the invention.

In the illustrative examples the proportions given are parts by weight.

Example 1.-Urea 840 parts, thiourea 300 parts, aqueous formaldehyde solution (formalin) 2400 parts. The solution contained 37.1 per cent actual formaldehyde and was used in practically neutral form with pH 5.6.

The urea and formaldehyde solution was mixed in the cold and heated under a reflux condenser to boiling point. Boiling was continued for 10 minutes, the temperature under these conditions being approximately 97.5 C. At the end of 10 minutes the thiourea was added and the boiling continued for a total period of 30 minutes. The hot solution was poured onto 730 parts of wood flour (the latter passing 20 mesh sieve). After being well mixed the wet mass was dried by spreading out on screens of Lionel metal placed in a drying chamber through which a gentle current of air was passed, the temperature ranging from up to 52 C. Drying was continued until the lumps of the material had a brittle feel and could be readily crushed or ground in a ball milL At this stage drying was considered complete and the batch was placed in a ball mill where it was ground for a period of about 1 hour until flne enough to pass a 40 mesh sieve.

This molding composition was then tested for its molding properties by conducting pressings at 1500 lbs. pressure per square inch and temperatures of the mold ranging from to 130 C. The pifiduct possessed an extremely good flow and yielded light brown shaped articles of a very attractive translucent appearance. Some of these specimens were pressed only to a semicured stage and then were baked for 3 days at a temperature of 65 C.

Example 2.The same proportions of raw materials were followed, the pH of the neutral formalin solution being 5.4 and the reaction at the boiling temperature being continued for a total of 45 minutes. 1280 parts of wood flour of relatively long fibre were used. This product after drying and grinding in the ball mill was found to mold nicely in thehot press at a temperature of C. employing a curing time of 6 minutes and a pressure of 1500 lbs. Some of the specimens made in this way were subsequently baked at 65 C.

Example 3.This molding composition contains a much higher proportion of wood flour. The conditions were much the same as in Examples 1 and 2, the same quantities of raw materials being used, the formaldehyde solution having a pH of 5.23 and the boiling being carried out for 30 minutes. The clear syrupy solution thus obtained was mixed with the wood flour and drying and grinding carried out in the same manner. The flow of this composition was not quite as free as that observed in the case of Examples 1 and 2, but was ad quate and enabled fairly good molded specimens to be obtained by hot pressing at 115 C. under a pressure of 1500 lbs.

Example 4.Using the same quantities of urea, thiourea and formaldehyde solution, the latter being in the zone of neutrality with a pH of 5.3.

A reaction period of boiling for 50 minutes yielded a syrupy solution which was divided into three parts. To one part there was added 10 per cent of wood flour based on the total solids in the solution. To another portion there was added 25 per cent of wood flour, while the third portion received no addition of wood flour. These three portions were all dried in a vacuum oven at a temperature of about 70 C. until sufliciently dry for molding. After drying and grinding, Dressing tests were conducted to determine which portion cured to best advantage. It was found that without the cellulose (wood flour) material the resin was too easily-liquefied and too slow in curing to be employed easily in molds having normal clearances. 0n hot-pressing the resin exuded from the mold to such an extent that the production of a good molded specimen of the required dimensions wasimpossible. The portion containing 10 per centof cellulose molded to better advantage, showing much less exudation and moderately good curing properties. There was, however, a slight degree of blistering observed. The portion containing 25 per cent ofcellulose cured nicely in the mold without blistering and furnished excellent molded specimens.

Example 5.-The same quantities of urea, thiourea and formaldehyde solution were used as in Example 1, the pH of the formaldehyde solution being 5.3 and the boiling period of reaction being 25 minutes. With the same quantities as employed in Example 1 the resulting syrup was used to impregnate 812 parts of alpha cellulose in sheet form. This was carried out by passing the sheets through the solution. Prior to such immersion a small amount of dye, namely, part of rhodamine, had been added to the syrup thereby causing the cellulose sheet to become dyed a strong pink. Approximately 1600 parts of the finished sheet stock was thus derived.

Example 6.In Example 5 the alpha cellulose sheet in dry form was impregnated with the syrup. In the present example the alpha sheet was first pulped in water and the syrup and pulp mixed. The formaldehyde solution used had the same pH value as in Example 5 and the boiling period was 30 minutes. It was noted that the pH of the paper pulp was 7.8 when it was mixed with the syrup. A very different product was obtained when the pulped material was thus incorporated with the syrup. On drying a product of a flocculent character which proved difficult to grind in the ball mill owing to its more spongy or stringy character was obtained. From the standpoint of ease of grinding, therefore, it is better to impregnate the cellulose stock when it is dry rather than when it has been first converted into a pulp with water. Aside from the somewhat greater difflculty of grinding, there is the further possibility that a highly flocculent or voluminous material is not as easy to mold. The amount of charge which can be placed in a given cavity is less and larger molds, therefore, have to be constructed. Densification of the molded material, therefore, is desirable and if this can be secured as a part of the normal manufacturing procedure the extra step of tableting is avoided, at least in the majority of cases. Of course, when a multi-colored molded article is required which is to be secured by placing in the mold tablets of different colors, the procedure of pre-forming or tableting may b utilized.

Example 7.'I'he alpha cellulose stock drives rather slowly when made in accordance with the procedure of Example 6. To shorten the time of drying the reaction mixture was boiled for a total period of 50 minutes. It was then found to dry in approximately half the time required when the reaction was carried on for only 25 or 30 minutes.

Example 8.A batch of syrup was made in a manner similar to Example 6, but the boiling was carried on for minutes to form a more viscous syrup. A portion of the syrup was withdrawn and used for the impregnation of alpha cellulose. 130 parts of this stock were used to absorb about 400 parts of the syrup, thereby taking up in the fibre approximately 260 parts of the resin on a dry basis. The remaining portion of the syrup was boiled until thetotal time of heating was minutes. A sheet of alpha cellu: lose 52 parts absorbed 160 parts of the reaction mixture, calculated on dry weight.

Example 9.--Using 840 parts urea, 300 parts thiourea and 2400 parts of formalin, the pH of the reaction mixture being within the neutral zone, namely, 5.3, the reaction was carried through a period of 50 minutes total time of boiling. A

15 small amount of sulphur rhodamine dye was added and alpha cellulose sheet stock was run through the hot syrup. The absorption which took place yielded an impregnated material containing approximately 33 per cent of cellulose. This was dried slowly between 40 and 50 C. until hard and crisp.

Example 10.-The weights used were the same as in Example 9,. butthe formalin was diluted with 6 volumes of water. The pH value was 6 and the boiling conducted for 60 minutes. .800 parts of wood flour having a long fibre were used to yield (calculated on the dryweight) approximately 75 per cent of the cellulose material.

When this had been thoroughly dried a small amount of zinc stearate was added'and thoroughly mixed in a ball mill. Grinding in the ball mill was not as complete as when fine wood flour is used, because the longer fibered material is more elastic and 'springy. This material was found to mold well under hot-pressing at C. When molded at 3,000 lbs. pressure a. good bit of reaction seemed to take place in the mold with the resulting absorption, solution or disappearance of fibre. Increasing the pressure under these circumstances aids such conversion or apparent change and the pressure, if desired, may be raised to 4,500 lbs. or higher in order to favor the change.

Example 11.A sheet of the impregnated alpha cellulose according to Example 9 was placed in the bottom of 'a mold and the high cellulosic product of Example 10, in powdered form, was charged into the mold above this sheet. On hot-pressing a rigid, panel-like product was secured, the thick and rigid backing of which was of a brownish color while the face was of a clear, translucent, pink shade.

Example 12.840 parts urea, 300 parts thiourea and 2250 parts formalin solution were used. In this case note that the proportion of the latter is reduced over that employed in the previous examples. The pH was 7.2 and the boiling conducted for 30 minutes. A fine grade of wood flour was incorporated with the syrup to yield approximately 36 per cent cellulose material based on the dry weight. on drying over night at about 60 C. a crisp product-was obtained which ground readily in the ball mill. Prior to drying, however, the batch was separated into two parts, to one of which was added a solution of barium ethyl sulphate equivalent to approximately 1 per cent of the dry weight.

The product containing the latent catalyzer when molded at C. and higher gave shaped articles which showed excellent resistance to boiling water. A product of this kind can be used to make various molded articles as such or employed as backing or support for cellulose sheet veneer.

Example 13.--The same proportions and quantitles were used as in Example 12, with the addition of 10 parts of light magnesium carbonate. The initial pH was 7. 0n heating gradually over a period of 10 or 12 minutes the pH was found to be 8.4 (the temperature then registering 65 0.). A boiling temperature was reached in 17 minutes, the pH registering 7.8. Thiourea was added and this required about 10 minutes to dissolve, being completely in solution 37 minutes from the time of starting the heating. The pH recorded at that time was 7.7. At the end of another 10 minutes, or 47 minutes in all from beginning of heating, the pH registering 7.6, 1,000 parts of fine wood flour were added. The composition was dried, ground in a ball mill with the addition of a small amount of zinc stearate. This composition was found to flow extremely well on hot-pressing. A portion of the product treated in the ball mill was moistened with water (with and without addition of catalyst), and dried. The product was found to have agglomerated into granules of notably greater density and compactness than the material coming from the ball mill. This granulated product is useful in molding operations where a substantial charge, without undue bulk, has to be introduced into the mold.

Example 14.The syrupy products obtained in the course of preparation of the foregoing compositions may be used as a glue for cementing wood veneer to its support, or for making laminated wood products. Thus the syrup obtained in Example 13 may be applied to one side of the sheet or veneer and this sheet glued onto a wooden support. In this way, while the veneered surface is wood, nevertheless the urea composition forms a part of such veneer and therefore is included within the scope of the present invention.

Example 15.ne part by weight of urea and 2 parts by weight of aqueous formaldehyde of about 40 per cent strength were used. pH of the formaldehyde was 7. Half of the urea was added to the formaldehyde at room temperature. Heat was then applied and when the temperature had reached about 90 C. the remainder of the urea was added. The temperature then was raised to the point of ebullition, which was approximately 95 C., and reaction was carried on for a period of 5 minutes. To the above reaction mixture of a part of wood flour was added and impregnation allowed to take place. The pH of the wood flour tested by leaching it with boiling water was .6. This composition was dried until the temperature in the drying oven reached 65 C. on testing in the hot press this composition showed a perfect flow in the die at a temperature of 125 C. and at much lower pressures. There was no sign of blisters. The resistance to boiling water of molded articles made from this composition was satisfactory.

Example 16.0ne part by weight of urea, 2 parts of formalin, pH 4.6, were used. The urea and formaldehyde were mixed at room temperature and heat applied. When the temperature reached 35 C., one-half of one per cent of light magnesium carbonate was added to the solution. The pH changed immediately to 7.8. The solution was reacted for 30 minutes at the boiling temperature and then was used to impregnate one part of wood flour (pH of extract obtained by boiling the wood flour at 100 C. was 6). The moist product was dried for 12 hours and was then found to grind well in the ball mill. Then there was added of one per cent of urea nitrate. The material thereupon flowed at 2 tons per square inch when pressed at 125 C. A perfect molding was obtained. In boiling water the molded article was unaffected by minutes exposure. To another portion of the same batch s of one per cent of orthophosphoric acid was added. The product cured nicely, flowing at somewhat higher pressures, however, but giving a perfect molded article. Exposure of the article in boiling water for minutes did not show deterioration. It should be noted that the urea nitrate and the phosphoric acid catalyst were best added by dissolving in a volatile solvent, such as methanol, and impregnatingthe molding composition therewith, then drying.

Example 17.2,000 parts formalin (37.5 per cent, pH 7), 747 parts of urea, 267 parts of thiourea. The urea and formaldehyde were mixed cold at room temperature and .5 per cent of magnesium carbonate was added. Heat was applied and 10 minutes after the reaction started the thiourea was added to the solution. 20 minutes later the solution was incorporated with 1,000 parts of wood flour (pH of the latter, obtained as above, is 6). Drying took about 18 hours and it was necessary to raise the temperature to 85 C. in order to dry out suiliciently so that grinding in a ball mill could be carried out. This material flowed at one ton per square inch. Water resistance good, 20 minutes exposure in boiling water showing no attack.

Example 18.One part by weight of urea, 2 parts of formalin, pH 7. The urea and formaldehyde were mixed at room temperature, brought to the boiling point and reacted for 20 minutes then used to impregnate one part of wood flour (pH 6, determined as above). The moist composition was dried rapidly until a temperature of about 65 C. was reached. Then there was added to it an equal weight of composition made according to Example 17, together with A of one per cent of urea nitrate. A good flow was obtained on pressing and the water resistance was excellent. The molded article was practically unaffected at the end of minutes.

Example 19.One part urea, 2 parts formalin, pH 4.8. Urea and fomfalin were mixed at room temperature, brought to boiling point and reacted for 10 minutes. part of wood flour was used for impregnation (pH 6, determined as above). Drying out in a well ventilated drying oven was carried on until the temperature of the mass reached about C. This material flowed well. On addition of urea nitrate as a catalyst, introducing 1 of one per cent by means of a methanol solution, the dried material flowed well in the press. In order to increase the flow, 5 per cent of urea on the weight of the total material, together with of one per cent of urea nitrate were added to another portion of the same batch, employing an alcoholic solution for impregnation. A very interesting result was obtained. While the initial pressure in the die appeared to be about 5 tons, it was noted that this dropped in the course of a few seconds as the urea plasticizer exerted action and the flow became free at as low as 2 tons, producing a. perfect molded article. By closing the die slowly the initial pressure indicated was 3 /2 tons, falling suddenly to 2 tons. This material had good water resistance and a 5 minute cure in the press gave molded articles which showed resistance greater than 30 minutes in boiling water.

Example 20.-Urea one part, formalin 2 parts. The latter had a pH of 7 and a strength of 37.5 per cent formaldehyde. This proportion of urea and formaldehyde corresponds to the formation of equimolecular proportions of monomethylol urea and dimethylol urea. I prefer to use as the principal thermo-plastic ingredient a ratio of this character, preferably having the pH so adjusted that the mixture of monomethylol urea and dimethylol urea will readily form.

The mixture was heated, reaching the point of ebullition in 15 minutes and being kept at that temperature for 10 minutes when per cent of wood flour (pH 6, obtained as above) was incorporated and drying carried on at a tenaperature gradually increasing to about C. over aperiod of 2 hours. The flow in the hot press was fairly good, breathing being necessary, however. On the addition of 3 per cent of lamp black breathing was not required. The addition of 3.5 per cent of lithopone accelerated the curing time. The lamp black, lithopone, Vermilion, or whatever pigment is used, preferably is admixed with the dried material in a ball mill.

Example 21.-When urea resin, with or without thiourea, is dried without any filling or extending agents, it is likely to form a hard glassy substance which is very difiicult to pulverize. It is possible to dry the concentrated syrup by spraying with heated air. A mixture of 400 parts by weight urea, 780 parts formalin, 37.5 per cent,

' pH 6.8, were heated under a refiux condenser for minutes, then the condenser was removed and the syrup boiled down until there remained about 900 parts. This was sprayed with heated air at 70 lbs. air pressure. A white sugary powder was secured .which was practically dry. This was mixed with wood flour together with a small percentage of zinc stearate and was molded. A portion of the sugary material was dried in the oven for several hours at 55 C. and also molded. This method of spraying permits of producing in pulverulent form a urea or urea-thiourea formaldehyde composition so that it may be easily incorporated with fillers, as by grinding together in a ball mill. In general it may be stated that best results in spray drying are secured when using aqueous formalin of about 40 per cent strength by carrying the concentration of the syrup to approximately half its initial volume.

The employment of urea. and formaldehyde in proportions equivalent to a mixture of equal parts of monoand dimethylol urea has been set forth. In other words, it is possible to react on urea with formaldehyde using a proportion of the latter greater than would be required to form monomethylol urea, but less than that needed for the complete conversion to dimethylol urea.

Further, various mixtures may be made of monoand dimethylol urea derivatives using substituted ureas acting in a similar or equivalent manner. For example, a mixture of (a) monomethylol thiourea and dimethylol urea, or (b) dimethylol thiourea with monomethylol urea, or (c) monoand dimethylol urea with monoand dimethylol thiourea.

I have called attention to the desirability of using for molding purposes a. mixture of monoand dimethylol urea in various proportions as, for example, the use of equal parts by weight. This proportion is equivalent to one mol of dimethylol urea to 1 mols monomethylol urea,

corresponding to a ratio of urea to formaldehyde of 4:2.86, that is, approximately in the ratio 4:3.

It should be noted that the latterratio calculated to a mixture of diand monomethylol urea corresponds to equimolecular proportions as indicated by the following reaction:

equivalent of equal parts by weight of the monoand dicompound.

In bringing about the reaction between urea and formalin the proper proportions required to make the mixed methylol ureas or their equivalents may be reacted together'or urea and formaldehyde may be separately reacted to form (a) monomethylol urea and (b) dimethylol urea or equivalent compounds. The liquids or products obtained by these reactions then may be mixed and incorporated with fibrous material containing cellulose.

Sometimes the reaction is desirably carried out in a medium of mixed aqueous and alcoholic components, methanol or acetone being suitable.

The employment of organic solvents to dissolve Translucency, oftentimes required, calls for effective penetration. Surprising results with pigmented wood flour thus may be obtained, the yellow to brown color imparted by ordinary wood flour to the complex being quite readily modified to pleasing tints of various sorts. Indications point to reaction, superficial or deep-seated, between the primary complex and the cellulose and/or lignin bodies present in ground wood.

Within the scope of the present invention thus there may be defined a process of making a resinous complex which comprises reacting on urea material (including resinifying derivatives and their mixtures), specifically urea, with a respon-l sive aldehyde, specifically formaldehyde normally in aqueous solution, preferably in the presence of some methanol, preferably conducting the reaction but, in a medium preferably of pH within the zone of litmus neutrality, using the aldehyde in a proportion greater than would be required to yield wholly monomethylol urea but less than would be required to form dimethylolurea, preferably incorporating the reaction material with cellulose fibre and drying at a temperature below 100 C. whereby a complex is obtained readily fiowable under suitable heat and pressure and hardening when so heated and pressed, thermosetting with especial ease when there is then present an acid catalyst of substantially complete resiniflcation.

What I claim is:

1. The process of making a resinous product which comprises reacting urea and formaldehyde in a proportion greater than would be required to form monomethylol urea but less than would be required to form dimethylol urea, in an aqueous medium of pH within the zone of litmus neutrality, incorporating the reaction mixture with cellulose fibre and drying at a temperature below 100 0.; whereby the product is obtained in a form readily flowable under pressure at a temperature approximately 120-140 C. and. hardening at such temperature to a substantially rigid resinous product.

2. A resinous product containing urea and formaldehyde condensation products in the proportion of approximately equivalent mols monoand dimethylol urea incorporated with a material consisting substantially of cellulose; said resinous product being capable of flowing and thermo-setting under heat and pressure to form a shaped article.

. methylolurea but less than that required to form dimethylolurea, and spray drying that product.

5. A product containing a spray-dried urea formaldehyde resin the urea and formaldehyde being present in a proportion greater than re- 'quired to form monomethyioiurea but less than that required to form dimethylolurea and a component consisting substantially of cellulose.

6. A substantially dry, thermo plastic condensation product of urea and formaldehyde, the urea and formaldehyde being present in a proportion greater than required to form monomethylolurea but less than that required to form dimethylolurea.

7. A resinous product containing a cellulosic filler impregnated with a urea-formaldehyde condensation product, the filler constituting from 50 to 80% of the product.

8. A resinous product containing a cellulosic iilier impregnated with urea-formaldehyde condensation product as binder component, the filler constituting from 50 to 80% of the resinous product, and part at least of the filler being thoroughly wetted with the binder component, whereby a product is obtained thermo setting under heat and pressure to a smooth article with part at least of the filler reacted to virtual disappearance.

9. A molding powder comprising a dry mixture of a filler impregnated with a urea formaldehyde condensation product and a minor amount of dry. pulverized thiourea.

10. Process of preparing a moldable composition comprising preparing an aqueous solution of arcane a urea formaldehyde condensation product, adding a filler, drying. and mixing a minor amount of pulverulent thiourea therewith.

11. A molding powder comprising a dry mixture of a celluiosic i'iller impregnated with aurea formaldehyde condensation product and a minor amount of thiourea.

12. A molding powder comprising a dry mixture of a filler impregnated with a urea formaldehyde condensation product and a minor amoimt of a urea compound, adapted to increase the flow of the condensation product during the molding operation.

13. A molding composition comprising a dry mixture of a filler impregnated with a urea-formaldehyde condensation product and thiourea in substantially unreacted condition, said composition. upon hot pressing yielding a shaped product of good surface. I

14. A molding composition comprising a ureaformaldehyde condensation product substantially free of volatiles, and a urea compound in subformaldehyde condensation product, and a fixing agent.

CARLE'I'ON ELLIS. 

